1 1 IDW 2004: IDW 2004: International Dimensional Workshop International Dimensional Workshop 010001000100 110101010011 010001000100 110101010011 010001000100 110101010011 010001000100 110101010011 Digital Metrology Solutions Copyright 2004 Digital Metrology Solutions, Inc. Dimensional Metrology Dimensional Metrology for for Functional Control Functional Control Mark C. Malburg, Ph.D. Digital Metrology Solutions, Inc. May 11, 2004 2 IDW 2004: IDW 2004: International Dimensional Workshop International Dimensional Workshop 010001000100 110101010011 010001000100 110101010011 010001000100 110101010011 010001000100 110101010011 Digital Metrology Solutions Copyright 2004 Digital Metrology Solutions, Inc.
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Dimensional MetrologyDimensional Metrologyforfor
Functional ControlFunctional Control
Mark C. Malburg, Ph.D.Digital Metrology Solutions, Inc.
May 11, 2004
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Most normal people…Most normal people…
… don’t want to make measurements.
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Measure Twice, Cut Once…Measure Twice, Cut Once…
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Even though you measure Even though you measure twice…twice…
What matters is the “What matters is the “cutcut””
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It’s not the measurement…It’s not the measurement…
It’s what you do with it.It’s what you do with it.
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A history of metrology A history of metrology for functional control…for functional control…
NOTE: Any resemblance to actual metrologists is purely coincidental.
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Where have we been?Where have we been?
• Metrology in the production setting has undergone some generational changes.
We are currently entering We are currently entering the 4the 4thth generation.generation.
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11stst GenerationGeneration
• The dawn of “trying and tweaking”
The generation of the craftsman.
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11stst GenerationGeneration
1. Make it.2. Try using it.
– If it works, keep it.– If it doesn’t work, go back to step #1.
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22ndnd GenerationGeneration
• The implementation of “simple gaging”
The generation of the gage block.
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22ndnd GenerationGeneration
• Produce the part based on simple dimensions and measurements
X.XXX
Y.YYY
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33rdrd GenerationGeneration
• The advent of “analysis”
The generation of GD&T.
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33rdrd GenerationGeneration
• Produce the part based on complex dimensional requirements– Measure the component
and provide a series of numbers and graphs associated with these requirements.
• Analysis– A Gaussian filter generates the waviness profile.– A circle is applied to the waviness profile.– The contact areas are determined.
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Socket GeometrySocket Geometry
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Crank Bearing LoadingCrank Bearing Loading
• A semi-rigid bearing is in contact with a crank pin. – Localized waviness generates highly stressed
areas.
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Crank Bearing LoadingCrank Bearing Loading
• Model:– Bandpass waviness.
• Data – Profile data points.
• Pre-processing– Leveling (LS Line)
• Analysis– A Gaussian filter generates the form profile.– A Gaussian filter generates the waviness profile.– Peak to valley form and waviness are controlled.
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Crank Bearing LoadingCrank Bearing Loading
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Corner Blending/SealingCorner Blending/Sealing
• A certain corner is critical to sealing. Too much blending can lead to leakage.
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Corner Blending/SealingCorner Blending/Sealing
• Model:– Maximum corner blend zone.
• Data – Profile data points.
• Pre-processing– Corner detection via 2nd derivates– Leveling of upper region
• Analysis– The linear seat region is detected via 2nd derivs. – The departure from ideal is reported as a
percentage of the available zone.
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Corner Blending/SealingCorner Blending/Sealing
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Effective Ring Groove AngleEffective Ring Groove Angle
• The functional ring groove is based on the seating of the piston ring on the peaks of the groove.
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Effective Ring Groove AngleEffective Ring Groove Angle
• Model:– Largest area between contacting peaks.
• Data – Profile data points.
• Pre-processing– Corner detection via 2nd derivates– Filtering with Gaussian filter.
• Analysis– A convex hull is applied to the waviness profile. – The largest facet of the hull is used to calculate the
functional angle.
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Effective Ring Groove AngleEffective Ring Groove Angle
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Contact LengthContact Length
• A certain surface has chamfered edges. A minimal contact length must be ensured for loading considerations.
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Contact LengthContact Length
• Model:– Determine the central (linear) region of a surface.
• Data – Profile data points.
• Pre-processing– Corner detection via 2nd derivates– Leveling of central region
• Analysis– The central, linear region is detected via a
combination of 2nd derivatives and a convex hull.
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Contact LengthContact Length
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Roller StressRoller Stress
• Crowned rollers are common used in highly stressed interfaces. The crown geometry must be controlled in order to reduce stress concentrations.
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Roller StressRoller Stress
• Model:– Two crowned geometries (cam & roller) in contact
at various alignments and loads.
• Data – Profile data points.
• Pre-processing– Leveling via LS fit of central region (optimization)
• Analysis– A Gaussian filter generates the waviness profile.– A stress analysis model is applied.
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Roller StressRoller Stress
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A Paradigm ShiftA Paradigm Shift
• In many cases, the direct control of a functional parameter represents a paradigm shift.
• Key elements:– “Marketing” – “Packaging”
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MarketingMarketing
• The direct control of functional attributes can be cost effective.– “What matters” can be
directly specified.– Reduced stress associated
with the judgment of non-conforming material.
– Increased freedom in manufacturing processdevelopment.
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PackagingPackaging
• The direct control of functional attributes requires some degree of graphical presentation in order to provide process control.